Surface Mount Technology for Process Analytic Sampling Systems Update 2003

Steve Doe, Parker Hannifin Corporation

Instrumentation

Surface Mount Technology Update 2003

Agenda:
Lessons

Learned Over Last 12 Months

Clusters

Functional Stream

Switch Options

Relative

System Cost Comparison: Conventional vs. Surface Mount

Beating

the Paradox

Surface Mount Technology Update 2003

Lessons Learned
11/8 defacto-standard

interface used by semiconductor

industry is not for us

Surface Mount Technology Update 2003

Lessons Learned
Costs are higher than conventionally plumbed systems
Cost challenge is

Chicken or Egg production paradox But also inherent cost adders such as additional parts for pressure indication
vs.

Surface Mount Technology Update 2003

Lessons Learned

Functional clusters
simplify flow paths for easier understanding in field

Surface Mount Technology Update 2003

Functional Clusters
Standardized Functions
FROM GRAB SAMPLE
N2 PURGE TO FLARE
PURGE GAS INLET

SAMPLE RETURN HEADE

CAL.STD.

- Fast Loop - Stream Switching

FILTER .5 micron

TO GRAB-SAMPLE SAMPLE INLET

STR 3 0M 1 0 EA BY -PA SS FLOW

PRESSU RE GAUGE

F I LTER
0
PRESSU RE GAUGE

30

TO DRAIN HEADER

OUT
WALLACE & TIERNAN 5125M

PRESSURE GAUGE

WALLACE & TIERNAN 5125M

30

- Analyzer Interface

FAST LOOP FLOW

STEAM

ANALYZER LOOP FLOW

FROM GC TO GC SIV

SQC STD.

ACTUATING AIR

PCA205 SAMPLE SYSTEM LAYOUT

GO

Surface Mount Technology Update 2003

FROM GRAB SAMPLE
N2 PURGE TO FLARE SAMPLE RETURN HEADER
PURGE GAS INLET

CAL.STD.

Functional Clusters
TO GRAB-SAMPLE
STR 3 0M 1 0 EA BY -PA SS FLOW
PRESSU RE GAUGE

FILTER .5 micron

F I LTER

Provide design flexibility

SAMPLE INLET

PRESSU RE GAUGE

30

TO DRAIN HEADER

OUT
WALLACE & TIERNAN 5125M

PRESSURE GAUGE

WALLACE & TIERNAN 5125M

30

FAST LOOP FLOW

STEAM

ANALYZER LOOP FLOW

FROM GC TO GC SIV

SQC STD.

ACTUATING AIR
SAMPLE RET URN HEADER
PURGE GAS INLET

PCA205 SAMPLE SYSTEM LAYOUT

FROM GRA B SA MPLE N2 PURGE TO FLA RE
FILTER .5 mic ron

CAL.STD.

WALLACE & TIERNAN 5125M

TO GRA B-SA MPLE SA MPLE INLET

ST A 0 RE 3 0M 1 B Y -PA SS FL OW

P R E S S U RE GAUGE

FILTER
0
P R E S S U RE GAUGE

30

FAST LOOP FLOW

TO DRAIN HEADER

FROM GRA B SA MPLE N2 PURGE TO FLA RE

WALLACE & TIERNAN 5125M

WALLACE & TIERNAN 5125M

FAST LOOP FLOW

TO GRA B-SA MPLE SA MPLE INLET

ST A 0 RE 3 0M 1 B Y -PA SS FL OW

P R E S S U RE GAUGE

FILTER
0
P R E S S U RE GAUGE

30

FAST LOOP FLOW

PRESSURE GAUGE

30
FROM GC

STEAM
SQC STD.

TO GC SIV

Surface Mount Technology Update 2003

Functional Clusters
Configurable based on your needs
SAMPLE BY-PASS FILTER SYSTEM (1-1/2" SUBSTRATE)
BY-PASS FLOW

Available as a part number ordered from your catalog of functions Provide functional standardization for ease of maintenance

RETURN PRESSURE

STREAM 1 BY-PASS FLOW

M OUNTING PLATE

FILTER WITH GAUGE MOUNTED ON BOWL

TO STREAM SWITCH

SAM PLE INLET

SUPPLY PRESSURE

5.75 in Fig. 1

5.19 in

Surface Mount Technology Update 2003

Functional Clusters
Stream Switching

Surface Mount Technology Update 2003

Stream Switch Options
Stream

Switching Valves Function:

Surface Mount Technology Update 2003

Stream Switch Options
Stream

Switching Valves Mortal Sin:

??

??

??

??
??

Cross Contamination!!!

Surface Mount Technology Update 2003

Stream Switches
Option -

Double (DBB) Block and Bleed Module 1: Double Block & Bleed
Leaking Seat
"OFF"
INLET

Fault tolerant Diagnostic capable

sample

OUTLET

VENT TO BUBBLER

VENT

Surface Mount Technology Update 2003

Stream Switches
DBB

Valves: Two Choices

ANSI/ISA76.00.02-2002 compliant?

R-Max: Is not geometrically compliant Is intent compliant

Diaphragm Valves: Total compliance Cost 65% more than R-Max But consider also...

Surface Mount Technology Update 2003

Stream Switches
Double

Block & Bleed Valves

Seat Geometry Comparison

R-Max:
Conically machined elastomer Engages radiused seat More contact area Contaminant induced leakage risk lower

Diaphragm Valves:
Donut machined seat Diaphragm seals on knife edge Less contact area Contaminant induced leakage risk higher

Surface Mount Technology Update 2003

Stream Switches
Option
-

2: Diaphragm Valve Manifold

Single diaphragm
valve for stream switch

- High integrity valve, but no safety net

-

Per stream cost

50% more than R-Max

Surface Mount Technology Update 2003

Stream Switch Options
Conclusions:

Diaphragm valves inherently more expensive & ultra high purity roots drive cost up further Stream cleanliness proportional to risk of cross contamination on single diaphragm valve manifold design Choose wisely

Surface Mount Technology Update 2003

Relative Cost Comparisons
CEMS project at
BLOWBACK NITROGEN ZERO NITROGEN INSTRUMENT AIR CAL. CALIBRATION GASES

Dow/Freeport
VENT
NC NC NC

GT-62 CEMS INLET SYSTEM DOW CHEMICAL CO. TEXAS DIVISION Rev.3 (9-3-02)

go

Several conventional systems in service Prototype NeSSI unit to evaluate for balance of project (18+ units)

NO

NO NC

NO NC

NC

OUT

FS-1 FM-2 FM-3

PS-1

PI-2
PRESSU R E G A U G E

F-1

PI-3
PRESSU R E G A U G E

PI-4
PRESSU R E G A U G E

FS-2 FM-4

LIQUID BARRIER FS-3 FM-5

P

AV
SAM PLE GA S C OOLER

FM-1

AV

Surface Mount Technology Update 2003

Relative Cost Comparisons
As supplied NeSSI-1

prototype user cost was 50% higher than conventional

Surface Mount Technology Update 2003

Cost Comparison Questions
Will NeSSI-1 functional
System Cost

savings outweigh procurement cost increase? Can NeSSI-1 advantages over conventional systems carry further development for NeSSI-2 & 3?

50%

Conv

Answers: Probably Not

Gen1 Gen2 Type of System

Gen3

Surface Mount Technology Update 2003

Beating the Paradox

NeSSI-1: Chicken or the Egg? What percent of analyzer sample systems are candidates for NeSSI-1 technology? approach conventional component volumes?
50%

When will NeSSI-1 volumes

Surface Mount Technology Update 2003

Beating the Paradox: Reducing Cost / Increasing Value

Reconfigured manual ball valve to eliminate higher cost diaphragm valves

50% savings in manual applications

Surface Mount Technology Update 2003

Beating the Paradox: Reducing Cost / Increasing Value

Zero-clearance fittings to simplify interconnects and function removal

Surface Mount Technology Update 2003

Beating the Paradox: Reducing Cost / Increasing Value
Eliminate

ultra-high-purity features from substrate block to reduce cost

Surface Mount Technology Update 2003

The Better We Reduce Cost & Increase Value...

The Better We Beat the Paradox!

Surface Mount Technology Update 2003